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| BS 638 :
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Arc welding power sources |
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Part 4. Specification for welding cables |
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ICS 25.160.30 |
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NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW
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BS 638 : Part 4 : 1996 Issue 2, September 1997

Committees responsible for this

British Standard
The preparation of this British Standard was entrusted to Technical Committee
WEE/6, Arc welding plant, upon which the following bodies were represented:

British Cable Makers' Confederation

Electricity Association
Health and Safety Executive
Institution of Electrical Engineers
National Association of Arc Welding Equipment Repairers
Power Generation Contractors' Association PGCA (BEAMA Ltd.)
Railway Industry Association
Welding Institute
Welding Manufacturers' Association (BEAMA Ltd.)

This British Standard, having

been prepared under the
direction of the Engineering
Sector Board, was published
under the authority of the
Standards Board and comes into
effect on
15 October 1996

 BSI 1997
Amendments issued since publication
First published as BS 638
December 1935 Amd. No. Date Text affected
Second edition December 1941
Third edition February 1954
Fourth edition December 1966 9640 September Indicated by a sideline in the margin
First published as BS 638 : Part 4 : 1997
January 1979
Second edition October 1996

The following BSI references

relate to the work on this
standard:
Committee reference WEE/6
Draft for comment 94/705808 DC

ISBN 0 580 24692 2

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BS 638 : Part 4 : 1996

Contents

Page
Committees responsible Inside front cover
Foreword iii
Section 1. General
1.1 Scope 1
1.2 References 1
1.3 Definitions 1
Section 2. Arc welding cables rated at 100 V a.c. r.m.s
2.1 Code designations 2
2.2 Rated voltage 2
2.3 Conductors 2
2.4 Covering 2
2.5 Overall diameter 2
2.6 Marking 2
2.7 Voltage test 4
2.8 Test under fire conditions 4
2.9 Static flexibility test 4
2.10 Test of the resistance to hot particles 4
2.11 Schedule of tests 4
Section 3. Arc welding cables rated for use up to 450 V a.c. r.m.s

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
3.1 Rated voltage 6
3.2 Conductors 6
3.3 Covering 6
3.4 Overall diameter 6
3.5 Marking 6
3.6 Voltage test 7
3.7 Test under fire conditions 7
3.8 Static flexibility test 7
3.9 Test of the resistance to hot particles 7
3.10 Schedule of tests 7
Annexes
A (informative) Guide to use 9
B (normative) Voltage test 13
C (normative) Static flexibility test 13
D (normative) Test of the resistance to hot particles 13
Tables
1 Constructional details for cables with flexible copper conductors 3
2 Constructional details for cables with extra flexible copper conductors 3
3 Constructional details for cables with aluminium or aluminium alloy
conductors 3
4 Values of maximum distance in static flexibility test 4
5 Schedule of test requirements for arc welding cables rated at 100 V a.c.
r.m.s 5
6 Constructional details of cables with flexible copper conductors 7
7 Constructional details of cables with aluminium or aluminium alloy
conductors 8
8 Schedule of test requirements for arc welding cables rated for use up to
450 V a.c. r.m.s 8

 BSI 1996 i
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BS 638 : Part 4 : 1996

A.1 Current rating for repeat cycle operation based on a 10 min period
(copper conductors) 10
A.2 Current rating for repeat cycle operation based on a 10 min period
(aluminium conductors) 10
A.3 Current rating for repeat cycle operation based on a 5 min period (copper
conductors) 11
A.4 Current rating for repeat cycle operation based on a 5 min period
(aluminium conductors) 11
A.5 Current rating for single cycle operation over a maximum period of 5 min
(copper conductors) 11
A.6 Current rating for single cycle operation over a maximum period of 5 min
(aluminium conductors) 11
A.7 Derating factors for a conductor temperature of 85 ÊC (free air, ambient
temperature 25 ÊC) 12
A.8 Derating factors for a conductor temperature of 60 ÊC (free air, ambient
temperature 25 ÊC) 12
A.9 Voltage drop in copper conductors at normal and elevated temperatures
(for guidance only) 12
A.10 Voltage drop in aluminium or aluminium alloy conductors at normal and
elevated temperatures (for guidance only) 12
A.11 Minimum handling temperature for covering materials 12
Figures

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
C.1 Static flexibility test apparatus 14
D.1 Device for testing resistance to hot particles 15
List of references Inside back cover

ii  BSI 1996
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BS 638 : Part 4 : 1996

Foreword

This Part of BS 638 has been prepared by Technical Committee WEE/6. It supersedes
BS 638 : Part 4 : 1979, which is withdrawn.
This Part is divided into three sections:
± a general section;
± a section implementing the European Harmonization Document HD 22.6 S2;
± a section on cables of national interest in the United Kingdom and not included in
HD 22.6 S2.
NOTE. Annex A is a guide to use (and implements Amendment No. 3 of HD 516.S1).

The other Parts of BS 638 are as follows.

Part 5: Specification for accessories
Part 7: Specification for safety requirements for installation and use
Part 8: Specification for electrode holders and hand held torches and guns for MIG,
MAG and TIG welding
Part 9: Specification for power sources for manual arc welding with limited duty
Part 10: Specification for safety requirements for arc welding equipment: welding
power sources
The preliminary drafting of this Part of BS 638 was undertaken by the BCMC to whom

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
due acknowledgement is made.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

 BSI 1996 iii

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ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

iv blank
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Section 1. General
1.1 Scope
This Part of BS 638 specifies requirements for single
core flexible cables carrying the welding current in arc
welding circuits.
Section 2 specifies requirements for arc welding cables
rated for connection between the industrial arc
welding power source and the electrode holder and
the workpiece in manual metal-arc welding. These
cables are rated at 100 V a.c. r.m.s. and 150 V d.c. This
section implements HD 22.6 S2 : 1995 and also includes
CENELEC recognized national types.
Section 3 specifies requirements for additional arc
welding cables widely used in the United Kingdom.
These cables are rated at 100 V a.c. r.m.s. and
150 V d.c. but undergo a higher voltage test and are
therefore capable of being used at voltages up to but
not exceeding 450 V a.c. r.m.s. or 675 V d.c., provided
they are suitably enclosed to protect the covering from
damage.
Annex A gives guidance on the selection of the size
and type of cables covered by this standard. This
annex implements Amendment No. 3 : 1993
to HD 516.S1.
NOTE 1. Recommendations for the protection of personnel from
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
welding hazards and safety precautions concerning arc welding
power sources are given in BS 638 : Part 7 and BS 638 : Part 10, to
which reference should be made.
NOTE 2. In section 2 and annex A the wording of the harmonized
documents has been amended in order to clarify the meaning.
1.2 References
1.2.1 Normative references
This Part of BS 638 incorporates, by dated or undated
reference, provisions from other publications. These
normative references are made at the appropriate
places in the text and the cited publications are listed
on the inside back cover. For dated references, only
the edition cited applies; any subsequent amendments
to or revisions of the cited publication apply to this
Part of BS 638 only when incorporated in the reference
by amendment or revision. For undated references, the
latest edition of the cited publication applies, together
with any amendments.
1.2.2 Informative references
This Part of BS 638 refers to other publications that
provide information or guidance. Editions of these
publications current at the time of issue of this
standard are listed on the inside back cover, but
reference should be made to the latest editions.
1.3 Definitions
For the purposes of this Part of BS 638, the definitions
given in BS 499 : Part 1 and BS 4727 : Part 2 : Group 08
apply, together with the following.
1.3.1 cable
A length of single-stranded covered insulated
conductor.
 BSI 1996
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BS 638 : Part 4 : 1996
1.3.2 conductor
The conducting portion of a cable consisting of a
group of wires assembled together and in contact with
each other.
1.3.3 arc welding power source
Equipment for supplying current and voltage with the
characteristics required for arc welding and allied
processes.
NOTE 1. An arc welding power source may also supply services to
other equipment and auxiliaries e.g. auxiliary power, cooling liquid,
consumable arc welding electrode and gas to shield the arc and
the welding area.
1.3.4 manual metal-arc welding (MMA welding)
Metal-arc welding with straight, covered electrodes of a
suitable length and applied by the operator without
automatic or semi-automatic means of replacement. No
protection in the form of a gas or mixture of gases
from a separate source is applied to the arc or molten
pool during welding.
1.3.5 automatic welding
Welding in which all the welding parameters are
automatically controlled. Manual adjustments may be
made between welding operations but not during
welding.
1.3.6 semi-automatic welding
Welding in which some of the welding parameters are
automatically controlled, but manual guidance is
necessary.
1.3.7 duty cycle
The ratio, for a given time interval, of the on-load
duration to the total time.
NOTE. This ratio, lying between 0 and 1, may be expressed as a
percentage.
1.3.8 single cycle operation
A single on-load period, not exceeding a specified time,
followed by a period in which the cable temperature
returns to ambient.
NOTE. In this Part of BS 638 , the maximum, single on-load period
is 5 min and the equipment usage is expressed as a percentage of
5 min.
1.3.9 repeat cycle operation
A periodically switched constant load with an on-load
period followed by an off-load period. This cycle is
repeated.
1.3.10 type tests
Tests made before supplying cable conforming to this
Part of BS 638 on a commercial basis in order to
demonstrate satisfactory performance characteristics to
meet the intended application.
NOTE. These tests need not be repeated unless changes are made
in the cable materials or design which might affect the
performance characteristics.
1.3.11 sample tests
Tests made on samples of completed cable, or
components taken from a completed cable to verify
that the finished products meet the design
specifications.
1
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BS 638 : Part 4 : 1996
Section 2. Arc welding cables rated at 100 V a.c. r.m.s.
2.1 Code designations
2.1.1 Harmonized types
Designations for harmonized arc welding cables rated
at 100 V a.c. r.m.s. are as follows:
± for cables with normal flexibility, HO1N2-D;
± for cables with extra high flexibility, HO1N2-E.
2.1.2 CENELEC recognized national types
Designations for national arc welding cables rated at
100 V a.c. r.m.s. are as follows:
± for cables with RS5 covering and normal flexibility,
AO1B-D.
± for cables with RS5 covering and extra high
flexibility, AO1B-E.
± for cables with EM5 covering and aluminium
conductors, AO1N2-A.
± for cables with RS5 covering and aluminium
conductors, AO1B-A.
2.2 Rated voltage
The rated voltage shall not exceed 100 V a.c. r.m.s.
between conductors or between conductor and earth.
NOTE. The corresponding d.c. voltage rating for these cables is
150 V.
2.3 Conductors
2.3.1 General
Conductors shall conform to either of the following.
a) For cables HO1N2-D, HO1N2-E, AO1B-D and
AO1B-E. The conductors shall be circular, plain or
tinned, annealed copper. They shall conform to
BS 6360, and shall be of multiple strand formation as
given in table 1 or table 2.
b) For cables AO1N2-A and AO1B-A. The
conductors shall be composed of hard drawn
aluminium, or aluminium alloy, wire of multiple
strand formation, the wire being plain or metal
coated, as given in table 3.
NOTE. The attention of purchasers and users is drawn to the
following limitations of aluminium conductors and of most
aluminium alloy conductors compared with copper conductors:
1) terminations should be suitable for use with the
conductors;
2) the service life is reduced if the cable is subjected to
repeated flexing;
3) the conductors are more liable to atmospheric corrosion;
4) the cable size is larger for similar electrical properties,
which may cause difficulties in mating with other items of
equipment manufactured in accordance with this Part of
BS 638.
The maximum conductor resistance shall be as given
in tables 1 to 3, as applicable.
1) CENELEC recognized national type.
2  BSI 1996
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2.3.2 Diameter of wires
The diameter of the wires in the conductor shall be
not greater than that given in tables 1 to 3, as
applicable.
NOTE. The conceptual construction number and the nominal
diameter of the wires in the conductor given in table 3 are for
information only. These formations were assumed in calculating
the maximum specified conductor resistances.
2.3.3 Separator
A separator consisting of a suitable material shall be
applied around the conductor.
NOTE. Embrittlement or discoloration of this separator after
vulcanization of the covering may be disregarded.
2.4 Covering
The covering shall be applied by extrusion around the
conductor and consist of two layers.
For coverings in one layer, the covering shall be of
rubber compound type EM5 or RS51) conforming to
BS 7655 : Section 2.4.
NOTE 1. The RS51) covering should be grey.
For coverings in two layers, the covering shall
comprise an outer layer of rubber compound type EM5
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
and an inner layer which shall be either of rubber
compound type EM5 or rubber compound type EI7
conforming to HD 22.1.S2.
NOTE 2. The ratio of thicknesses of the two layers is not
specified.
Full testing shall be carried out on both layers, except
where the resulting sample from the inner layer is less
than 0.8 mm thick. In this case full testing shall be
carried out on the outer layer and only the hot set test
shall be carried out on the inner layer.
The thickness of covering shall be as given in tables 1
to 3, as applicable.
2.5 Overall diameter
The overall diameter of the cable shall be as given in
tables 1 to 3, as applicable.
2.6 Marking
2.6.1 General
The outer covering shall be marked, by printing,
indenting or embossing, with the following:
a) the appropriate code designation (in accordance
with 2.1); and
b) the cross-sectional area (in mm2) of the
conductor.
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Section 2 BS 638 : Part 4 : 1996

Table 1. Constructional details for cables with flexible copper conductors

Conductor Total radial Mean overall diameter Max. conductor resistance per
thickness of 1000 m at 20 ÊC
Nominal Maximum covering Lower limit Upper limit Tinned wires Plain wires
cross-sectional diameter of
area wires
mm2 mm mm mm mm V V
10 0.21 2.0 7.7 9.7 1.95 1.91
16 0.21 2.0 8.8 11.0 1.24 1.21
25 0.21 2.0 10.1 12.7 0.795 0.780
35 0.21 2.0 11.4 14.2 0.565 0.554
50 0.21 2.2 13.2 16.5 0.393 0.386
70 0.21 2.4 15.3 19.2 0.277 0.272
95 0.21 2.6 17.1 21.4 0.210 0.206
120 0.51 2.8 19.2 24.0 0.164 0.161
150 0.51 3.0 21.1 26.4 0.132 0.129
185 0.51 3.2 23.1 28.9 0.108 0.106
NOTE. This table applies to both harmonized and CENELEC recognized national types.

Table 2. Constructional details for cables with extra flexible copper conductors
Conductor Total radial Mean overall diameter Max. conductor resistance per
thickness of 1000 m at 20 ÊC
Nominal Maximum covering Lower limit Upper limit Tinned wires Plain wires
cross-sectional diameter of
area wires
mm2

10
16
25
mm

0.16
0.16
0.16
mm

1.2
1.2
1.2
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
mm

6.2
7.3
8.6
mm

7.8
9.1
10.8
V
1.95
1.24
0.795
V
1.91
1.21
0.780
35 0.16 1.2 9.8 12.3 0.565 0.554
50 0.16 1.5 11.9 14.8 0.393 0.386
70 0.16 1.5 13.6 17.0 0.277 0.272
95 0.16 1.8 15.6 19.5 0.210 0.206
120 0.21 1.8 17.2 21.6 0.164 0.161
150 0.21 1.8 18.8 23.5 0.132 0.129
185 0.21 1.8 20.4 25.5 0.108 0.106
NOTE. This table applies to both harmonized and CENELEC recognized national types.

Table 3. Constructional details of cables with aluminium or aluminium alloy conductors

Conductor Total radial Mean overall diameter Max. conductor
Nominal Conceptual Maximum thickness of Lower limit Upper limit resistance per
cross-sectional construction diameter of covering 1000 m at 20 ÊC
area number1) and wires
nominal
diameter of
wires
mm2 No./mm mm mm mm mm V
25 154/0.45 0.46 2.0 10.0 13.0 1.25
35 217/0.45 0.46 2.0 11.0 14.5 0.886
50 312/0.45 0.46 2.2 13.0 17.0 0.616
70 437/0.45 0.46 2.4 15.0 19.0 0.440
95 589/0.45 0.46 2.6 17.0 21.5 0.326
120 756/0.45 0.46 2.8 19.0 24.5 0.254
150 925/0.45 0.46 3.0 21.0 26.5 0.208
240 1525/0.45 0.46 3.4 26.0 33.0 0.126
NOTE 1. This table applies to CENELEC recognized national types.
1) Provided for information only (see 2.3.2).

 BSI 1996 3
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BS 638 : Part 4 : 1996 Issue 2, September 1997 Section 2

The marking shall be such that the gap between the Table 4. Values of maximum distance in static
end of one complete inscription and the beginning of flexibility test
the next does not exceed 550 mm.
Nominal Maximum distance l9
NOTE. For the UK market, cables may be additionally marked by cross-sectional
printing, indenting or embossing with: Class D conductors Class E conductors
area
| 1) the number of the standard and section, i.e. BS 638-4 S2;
(normal
flexibility)
(extra high
flexibility)
| 2) the type of conductor (Cu for copper or Al for aluminium). mm2 cm cm
2.6.2 Indication of origin 10 65 45
All cables shall be provided with an indication of 16 65 45
origin consisting of an identification thread or threads
or the continuous marking of the manufacturer's name 25 65 45
or trademark. 35 75 50
If coloured threads are used, the colours shall conform 50 75 50
to those registered in PD 2379 where applicable. The
colours shall be easy to recognize or easily made 70 80 55
recognizable, if necessary, by cleaning with a solvent, 95 90 60
for example petrol. 120 110 75
The manufacturer's name or trademark shall be 150 130 90
marked, if used, either by printing on a separate tape
or by printing, indenting or embossing on the covering. 185 150 95
The marking shall be regarded as continuous if the gap
between the end of one complete inscription and the
beginning of the next does not exceed:
2.10 Test of the resistance to hot
a) 550 mm if the marking is on the covering;
particles

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
The covering of the cables shall not ignite nor be
b) 275 mm in all other cases.
completely penetrated when tested in accordance with
annex D using a test voltage of 1000 V a.c. r.m.s. In
2.7 Voltage test addition the heated rod shall not have penetrated into
When tested in accordance with B.1, there shall be no the covering so that it contacts the conductor of the
voltage breakdown. cable. If the gases emitted from the covering during the
test are flammable, the burning shall not continue for
longer than 15 s after the heated rod is removed.
2.8 Test under fire conditions Following this test the cable shall be tested in
Cables with a type EM5 covering shall conform to accordance with B.1. There shall be no voltage
BS 4066 : Part 1. breakdown.

2.9 Static flexibility test 2.11 Schedule of tests

2.9.1 Cables with copper conductors shall be tested Tests shall be carried out in accordance with the
in accordance with annex C. schedule given in table 5.
NOTE. The test does not apply to cables with aluminium or
aluminium alloy conductors.
The calculated mean value of l9 shall be not greater
than the maximum value given in table 4.
2.9.2 If the mean value of l9 is greater than the value
given in table 4, the sample shall be pre-conditioned by
the method described in C.3. After this
pre-conditioning, the sample shall be re-tested in
accordance with C.2 and, for acceptance, shall
conform to 2.9.1.

| 2) Marking `BS 638-4. S2' (BS 638 : Part 4 : Section 2) on or in relation to a product represents a manufacturer's declaration of
conformity, i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of the standard. The accuracy of
the claim is solely the claimant's responsibility. Such a declaration is not to be confused with third party certification of conformity,
which may also be desirable.

4  BSI 1997
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Section 2 BS 638 : Part 4 : 1996

Table 5. Schedule of test requirements for arc welding cables rated at 100 V a.c. r.m.s
Test Requirements (clause Test method Test category
number) EM5 RS5
Tests on components:
conductor construction 2.3 Visual examination T, S T, S
conductor resistance 2.3.1 BS 6360 T, S T, S
separator 2.3.3 Visual examination T, S T, S
covering
a) material 2.4 BS 7655 : section 2.4 : 1993 T T
b) thickness 2.4 BS 6469 : section 1.1 : 1992 T, S T, S
c) overall diameter 2.5 BS 6469 : section 1.1 : 1992 T, S T, S
Tests on completed cables:
cable marking 2.6 Visual examination T, S T, S
voltage test 2.7 Annex B T, S T, S
Under fire conditions: vertical 2.8 BS 4066 : Part 1 : 1980 T Ð
burning (single cable)
static flexibility (copper 2.9 Annex C T T
conductors only)
resistance to hot particles 2.10 Annex D T T

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
T = type tests
S = sample tests

 BSI 1996 5
 .. ..
BS 638 : Part 4 : 1996
Section 3. Arc welding cables rated for use up to 450 V a.c.
r.m.s.
3.1 Rated voltage
This cable is recognized for welding duty at voltages to
earth not exceeding 100 V a.c. r.m.s. value. This
limitation does not however apply to the voltage
produced by a superimposed high frequency supply or
other similar low power device used for starting or
stabilizing an arc. When required the cable may be
used at voltages above 100 V a.c. r.m.s. but not
exceeding 450 V a.c. r.m.s. and, in these cases, it shall
be adequately protected from damage to the covering.
NOTE. the corresponding d.c. voltage ratings for these cables is
150 V and 675 V.
3.2 Conductors
3.2.1 General
The conductors shall be circular, plain or tinned,
annealed copper. Flexible conductors shall comply
with BS 6360, and shall be of multiple strand formation
as given in table 6.
Alternatively, the conductors shall be composed of
hard drawn aluminium, or aluminium alloy, wire of
multiple strand formation, the wire being plain or
metal coated, as given in table 7.
NOTE. The attention of purchasers and users is drawn to the
following limitations of aluminium conductors and of most
aluminium alloy conductors compared with copper conductors:
1) terminations should be suitable for use with the
conductors;
2) the service life is reduced if the cable is subjected to
repeated flexing;
3) the conductors are more liable to atmospheric corrosion;
4) the cable size is larger for similar electrical properties,
which may cause difficulties in mating with other items of
equipment manufactured in accordance with BS 638.
The maximum conductor resistance shall be as given
in tables 6 and 7, as applicable.
3.2.2 Diameter of wires
The diameter of the wires in the conductor shall be
not greater than that given in tables 6 and 7, as
applicable.
NOTE. The conceptual construction number and nominal diameter
of the wires in the conductor, given in table 7, are for information
only. These formations were assumed in calculating the maximum
specified conductor resistances.
3.2.3 Separator
A separator consisting of a suitable material shall be
applied around the conductor.
NOTE. Embrittlement or discoloration of this separator after
vulcanization of the covering may be disregarded.
| 3) Marking `BS 638-4.S3' (BS 638 : Part 4 : Section 3) on or in relation to a product represents a manufacturer's declaration of conformity,
i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of the standard. The accuracy of the claim is
solely the claimant's responsibility. Such a declaration is not to be confused with third party certification of conformity, which may also
be desirable.
6 BSI 1997
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Issue 2, September 1997
3.3 Covering
The cables shall have a covering consisting of an outer
layer of EM5 sheathing compound conforming to
BS 7655 : Section 2.4 or RS3 sheathing compound
conforming to BS 7655 : Section 2.3. They shall have an
inner layer of GP4 insulating compound conforming to
BS 7655 : Section 1.2.
NOTE 1. When these cables are used at voltages above 100 V a.c.
r.m.s. but not exceeding 450 V a.c. r.m.s. they should be suitably
enclosed to protect them from damage to the covering.
NOTE 2. The outer layer should be orange or black.
The thickness of covering shall be as given in tables 6
and 7, as applicable.
The mean total radial thickness of covering shall be
not less than the value in table 6 or table 7, as
applicable, and the smallest measured value shall not
fall below the tabulated value by more than
15 % + 0.1 mm, i.e. the smallest measured value (in mm)
shall be not less than:
t 3 15 + 0.1
tv 2 v
 100 
where
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
tv is the tabulated value (in mm).
In composite coverings the outer layer shall be 60 % to
80 % of the total thickness.
3.4 Overall diameter
The overall diameter of the cable shall be as given in
table 6 or table 7, as applicable.
3.5 Marking
3.5.1 The outer covering of all types shall be marked,
by printing, indenting or embossing, with:
a) the number of the standard and section, |
i.e. BS 638-4.S33);
b) the numerical value of the nominal area of the
conductor in square millimetres; and
c) the type of conductor (Cu for copper or Al for
aluminium).
The marking shall be such that the gap between the
end of one complete inscription and the beginning of
the next does not exceed 550 mm.
 .. .. .. .... ... ....
..

Section 3 BS 638 : Part 4 : 1996

3.5.2 Indication of origin
All cables shall be provided with an indication of
origin consisting of an identification thread or threads
or the continuous marking of the manufacturer's name
or trademark.
If coloured threads are used, the colours shall conform
to those registered in PD 2379 where applicable. The
colours shall be easy to recognize or easily made
recognizable, if necessary, by cleaning with a solvent,
for example petrol.
The marking of the manufacturer's name or trademark,
if used, shall be either by printing on a separate tape
or by printing, indenting or embossing on the covering.
The marking shall be regarded as continuous if the gap
between the end of one complete inscription and the
beginning of the next does not exceed:
a) 550 mm if the marking is on the covering;
b) 275 mm in all other cases.
3.8.2 If the calculated mean value of l9 is greater than
the value given in table 4, the sample shall be
pre-conditioned by the method described in C.3. After
this pre-conditioning, the sample shall be re-tested in
accordance with C.2 and, for acceptance, shall
conform to 3.8.1.
3.9 Test of the resistance to hot particles
The covering of the cables shall not ignite nor be
completely penetrated when tested in accordance with
annex D using a test voltage of 3000 V a.c. r.m.s. In
addition, the heated rod shall not have penetrated into
the covering so that it contacts the conductor of the
cable. If the gases emitted from the covering during the
test are flammable, the burning shall not continue for
longer than 15 s after the heated rod is removed.
Following this test, the cable shall be tested in
accordance with B.1. There shall be no voltage
breakdown.

3.6 Voltage test 3.10 Schedule of tests

When tested in accordance with B.2.1 or B.2.2 there
Tests shall be carried out in accordance with the
shall be no voltage breakdown.
schedule given in table 8.

3.7 Test under fire conditions

Cables shall conform to BS 4066 : Part 1.

3.8 Static flexibility test

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
3.8.1 Cables with copper class D conductors shall be
tested in accordance with annex C.
NOTE. The test does not apply to cables with aluminium or
aluminium alloy conductors.
The calculated mean value of l9 shall be not greater
than the maximum value given in table 4.

Table 6. Constructional details of cables with flexible copper conductors

Conductor Total radial Mean overall diameter Max. conductor resistance per
thickness of 1000 m at 20 ÊC
Nominal Maximum covering Lower limit Upper limit Tinned wires Plain wires
cross-sectional diameter of
area wires
mm2 mm mm mm mm V V
10 0.21 2.0 7.8 10.0 1.95 1.91
16 0.21 2.0 9.0 11.5 1.24 1.21
25 0.21 2.0 10.0 13.0 0.795 0.780
35 0.21 2.0 11.5 14.5 0.565 0.554
50 0.21 2.2 13.0 17.0 0.393 0.386
70 0.21 2.4 15.0 19.0 0.277 0.272
95 0.21 2.6 17.5 21.5 0.21 0.206
120 0.51 2.8 19.5 24.0 0.164 0.161
150 0.51 3.0 21.5 26.0 0.132 0.129
185 0.51 3.2 23.0 29.0 0.108 0.106

 BSI 1996 7
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BS 638 : Part 4 : 1996 Section 3

Table 7. Constructional details of cables with aluminium or aluminium alloy conductors

Conductor Total radial Overall diameter Max. conductor
Nominal Conceptual Maximum thickness of Lower limit Upper limit resistance per
cross-sectional construction diameter of covering 1000 m at 20 ÊC
area number1) and wires
nominal
diameter of
wires
mm2 No./mm mm mm mm mm V
25 154/0.45 0.46 2.0 10.0 13.0 1.25
35 217/0.45 0.46 2.0 11.0 14.5 0.886
50 312/0.45 0.46 2.2 13.0 17.0 0.616
70 437/0.45 0.46 2.4 15.0 19.0 0.440
95 589/0.45 0.46 2.6 17.0 21.5 0.326
120 756/0.45 0.46 2.8 19.0 24.5 0.254
150 925/0.45 0.46 3.0 21.0 26.5 0.208
240 1525/0.45 0.46 3.4 26.0 33.0 0.126
1) Provided for information only (see note to 3.2.2).

Table 8. Schedule of test requirements for arc welding cables rated for use up to 450 V a.c. r.m.s.
Test Requirements (clause Test method Test category
number)
Tests on components:
Conductor construction
Separator
Covering:
3.2
3.2.3
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Visual examination
Visual examination
T, S
T, S

a) material 3.3 BS 7655 : Sections 1.2, 2.3 and T

2.4 : 1993
b) thickness 3.3 BS 6469 : section 1.1 : 1992 T, S
c) overall diameter 3.4 BS 6469 : section 1.1 : 1992 T, S
Tests on completed cables
Conductor resistance 3.2.1 BS 6360 : 1991 T, S
Cable marking 3.5 Visual examination T, S
Voltage test 3.6 Annex B T, S
Under fire conditions: vertical 3.7 BS 4066 : Part 1 : 1980 T
burning (single cable)
Static flexibility(copper conductors 3.8 Annex C T
only)
Resistance to hot particles 3.9 Annex D T
T = type test
S = sample test

8  BSI 1996
 .. .. ..
Annexes
Annex A (informative)
Guide to use
A.1 General
The cables specified in this standard are suitable for
general use in dry, humid or moist conditions, indoors
or outdoors, including industrial and agricultural
locations, construction sites and shipyards.
The information in A.2 to A.4 is given to assist the
user in selecting the most suitable size and type of
welding cable.
A.2 Selecting the cable size
A.2.1 General
The cable size is usually chosen on the basis of the
current rating at the duty cycle required.
A.2.2 Duty cycle
Welding equipment conforming to BS 638 is rated for
repeat cycle operation based on a 10 min period, and
the cable should be selected according to this rating
(see tables A.1 and A.2). Where the duty cycle of the
power source or particular application is not known it
can be assumed that for manual welding the duty cycle
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
will be between 35 % to 60 %. Duty cycles of 85 % to
100 % may be achieved in automatic welding.
When authorized by the equipment manufacturer or
competent person a repeat cycle based on a 5 min
period or 5 min single cycle may be used. Ratings for
copper cables and aluminium cables based on these
periods are given in tables A.3, A.4, A.5 and A.6.
For percentage duty cycles not stated in the tables, the
next higher percentage duty cycle rating should be
used or reference should be made to the cable
manufacturer.
A.2.3 Temperature
The current ratings given in the tables are for cables in
free air at an ambient temperature of 25 ÊC and a
conductor temperature of 85 ÊC.
Where the ambient temperature differs from 25 ÊC, the
current should be derated by multiplying it by the
appropriate factor shown in table A.7.
NOTE 1. Where cables operate with a conductor temperature of
85 ÊC, the outer covering may reach 80 ÊC. Cables operating at this
temperature may cause damage to other types of cable coverings
and may cause burn injuries if touched. Suitable precautions
should be taken to segregate such cables to prevent these hazards.
To allow the operator to handle the cable during use,
with suitable gloves, a maximum conductor
temperature of 60 ÊC is advisable.
For arc welding cables in free air at an ambient
temperature of 25 ÊC and a conductor temperature of
60 ÊC, the ratings in tables A.1, A.3, A.5 and A.6 shall be
derated by a factor of 0.76. If the ambient temperature
differs from 25 ÊC, the 60 ÊC adjusted rating should be
further corrected by multiplying it by the appropriate
factor shown in table A.8.
 BSI 1996
.... ... ....
..
BS 638 : Part 4 : 1996
A.2.4 Voltage drop
Where long cable runs are involved, it may be
necessary to choose the cable size on the basis of the
voltage drop. Tables A.9 and A.10 give voltage drop
values for both copper and aluminium conductors and
three typical conductor temperatures. The values given
are for 10 m of cable carrying 100 A. For longer cable
lengths and higher currents, the values should be
increased pro rata. Excessive voltage drop may result
in reduction in the selected welding current and/or
deterioration of welding conditions.
The values in tables A.9 and A.10 apply to direct
current only. With alternating current the values will be
higher, the amount depending on the spacing between
the welding and return cables. To minimize the effects
of alternating current on voltage drop, the two cables
forming the welding circuit should be kept as close
together as possible and not coiled.
NOTE. Where cables of an adequate current capacity are not
available two or more cables may be used in parallel. These
cables should be of the same type, cross-sectional area and length
to ensure adequate current sharing. The total nominal area of the
cable should be at least equivalent to the values given in the
appropriate table.
A.3 Conductor flexibility
Flexible and extra high flexible copper cables are
suitable for connections direct to electrode holders for
MMA welding. Flexible copper cables are also used for
connection to appropriate types of equipment for
semi-automatic and automatic welding and, in addition,
to connect the work piece to the power source.
Aluminium cables, when used, are subject to fracturing
of conductors when repeatedly flexed; they may be
difficult to join; they are subject to corrosion; and they
are generally less flexible than the equivalent related
copper cables. However, they are lighter than copper
cables.
A.4 Choice of covering material
A.4.1 Wear resistance
Covering materials specified in this standard have good
mechanical properties and will give a satisfactory life
under flexing. The actual life obtained from the cable
is usually determined by mechanical damage and
severe abrasion. Where the cables are used for hand
welding and are dragged over rough surfaces or sharp
edges, the cable life may be only a few months, but
where there is some protection against severe wear
and mechanical damage, e.g. where the cable forms
part of a welding machine, then the cable may last for
many years. Outer coverings of type EM5 or RS3 are
generally more durable than those of type RS5 under
severe mechanical conditions.
9
 .. .. .. .... ... ....
..

BS 638 : Part 4 : 1996 Annex A

A.4.2 Resistance to oil and greases A.4.4 Heat resistance

Outer coverings of type EM5 or RS3 are resistant to
oils, greases, acids, alkalies, and to a wide range of
aggressive substances. These covering materials should
be chosen when the cables are used in places such as
workshops, where they may come into contact with
oil, grease etc.
It should be noted that these materials may deteriorate
if immersed in oil or other aggressive substances. The
amount of deterioration will depend on the type of
substance, temperature, and the length of time for
which the materials are immersed.
Covering materials consisting of RS5 should not be
used where extensive contact is expected with oils,
greases and other aggressive substances.
A.4.3 Reduced flame propagation
Outer coverings of type EM5 or RS3 have reduced
flame propagation. Covering materials based on RS5
have no reduced flame propagation properties.
The covering materials in this standard are suitable for
a normal working life at a maximum working
temperature of 85 ÊC. Higher operating temperatures
will shorten the life of the cable.
The specified covering materials are resistant to weld
spatter.
A.4.5 Low temperature flexibility
Most materials become less flexible as the temperature
is reduced. It is generally considered that the cables
specified in this standard can be used down to the
temperatures given in table A.11.
A wide range of materials has been, and is being, used
for welding cable coverings. The materials specified in
this standard are crosslinked elastomeric compounds
which are considered to have the best thermal
properties for flexible cable coverings for welding.
PVC is not recommended for use as a welding cable
covering as it can become stiff and brittle at
temperatures around 0 ÊC and, as with other
thermoplastic coverings, it can also be easily damaged
by contact with hot metal or hot particles.

Table A.1 Current rating for repeat cycle operation based on a 10 min period (copper conductors)

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Current rating at various duty cycles
Nominal 100 % 85 % 80 % 60 % 35 % 20 % 8%
cross-sectional
area
mm2 A A A A A A A
10 100 100 100 101 106 118 158
16 135 136 136 139 150 174 243
25 180 182 183 190 213 254 366
35 225 229 231 243 279 338 497
50 285 293 296 316 371 457 681
70 355 367 373 403 482 602 908
95 430 448 456 498 606 765 1164
120 500 524 534 587 721 917 1404
150 580 610 622 689 853 1090 1676
185 665 702 717 797 995 1277 1971

Table A.2 Current rating for repeat cycle operation based on 10 min period (aluminium
conductors)
Nominal 100 % 85 % 80 % 60 % 35 % 20 % 8%
cross-sectional
area
mm2 A A A A A A A
25 140 141 141 144 155 179 250
35 175 177 177 183 203 239 341
50 225 228 230 240 272 326 474
70 275 282 284 302 351 430 637
95 335 345 350 376 446 553 830
120 390 404 410 444 534 669 1011
150 455 474 482 525 637 803 1220
240 600 632 645 714 886 1134 1744

10  BSI 1996
 .. .. .. .... ... ....
..

Annex A BS 638 : Part 4 : 1996

Table A.3 Current rating for repeat cycle operation based on a 5 min period (copper conductors)
Current rating at various duty cycles
Nominal 100 % 85 % 80 % 60 % 35 % 20 % 8%
cross-sectional
area
mm2 A A A A A A A
10 100 101 102 106 119 143 206
16 135 138 140 148 173 212 314
25 180 186 189 204 244 305 460
35 225 235 239 260 317 400 608
50 285 299 305 336 415 529 811
70 355 375 383 426 531 682 1053
95 430 456 467 523 658 850 1319
120 500 532 545 613 776 1006 1565
150 580 619 634 716 911 1184 1845
185 665 711 729 826 1054 1374 2145

Table A.4 Current rating for repeat cycle operation based on 5 min period (aluminium conductors)
Nominal 100 % 85 % 80 % 60 % 35 % 20 % 8%
cross-sectional
area
mm2
25
35
50
A
140
175
225
A
143
180
234
A
145
183
237
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
A
153
196
257
A
178
233
310
A
218
289
389
A
323
433
589
70 275 288 293 322 395 502 767
95 335 353 360 399 495 633 975
120 390 412 421 469 587 755 1166
150 455 482 493 552 694 896 1388
240 600 640 656 742 944 1228 1915

Table A.5 Current rating for single cycle Table A.6 Current rating for single cycle
operation over a maximum period of 5 min operation over a maximum period of 5 min
(copper conductors) (aluminium conductors)
Current rating at various duty cycles Current rating at a maximum duty cycle of
Nominal 100 % 85 % 60 % 35 % Nominal 100 % 85 % 65 % 35 %
cross-sectional cross-sectional
area area
mm2 A A A A mm2 A A A A
10 100 103 108 122 25 140 150 180 240
16 135 145 175 230 35 175 190 225 295
25 180 195 230 300 50 225 245 290 380
35 225 245 290 375 70 275 300 355 465
50 285 305 365 480 95 335 365 430 570
70 355 385 460 600 120 390 425 500 660
95 430 470 560 730
150 455 495 590 770
120 500 540 650 850
240 600 650 775 1015
150 580 630 750 980
185 665 720 860 1120

 BSI 1996 11
 .. .. .. .... ... ....
..

BS 638 : Part 4 : 1996 Annex C

Table A.7 Derating factors for a conductor Table A.10 Voltage drop in aluminium or
temperature of 85 ÊC (free air, ambient aluminium alloy conductors at normal and
temperature 25 ÊC) elevated temperatures
(for guidance only)
Ambient temperature Factor
ÊC Nominal D.C.1) voltage drop/100 A/10 m of cable at
cross- 20 ÊC 60 ÊC 85 ÊC
30 0.96 sectional
35 0.91 area of
aluminium
40 0.87 conductor
45 0.82 mm2 V V V
25 1.248 1.45 1.58
Table A.8 Derating factors for a conductor 35 0.886 1.03 1.12
temperature of 60 ÊC (free air, ambient 50 0.616 0.715 0.778
temperature 25 ÊC)
70 0.440 0.511 0.555
Ambient temperature Factor
ÊC 95 0.326 0.379 0.411
30 0.92 120 0.254 0.295 0.321
35 0.84 150 0.208 0.242 0.263
40 0.75 240 0.126 0.146 0.159
1) The corresponding values when using a.c. may be much
45 0.65
higher, depending on the configuration of the cables.

Table A.9 Voltage drop in copper conductors at

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
normal and elevated temperatures (for guidance Table A.11 Minimum handling temperature for
only) covering materials
Nominal D.C.1) voltage drop/100 A/10 m of cable at Covering materials (see 2.4 and Temperature
cross- 3.4) ÊC
20 ÊC 60 ÊC 85 ÊC
sectional
area of EM5 220
copper
conductor
RS5 240
mm2 V V V GP4/RS3 220
10 1.950 2.260 2.450 GP4/EM5 220
16 1.240 1.430 1.560
25 0.795 0.920 0.998
35 0.565 0.654 0.709
50 0.393 0.455 0.493
70 0.277 0.321 0.348
95 0.210 0.243 0.264
120 0.164 0.190 0.206
150 0.132 0.153 0.166
185 0.108 0.125 0.136
1) The corresponding values when using a.c. may be much
higher, depending on the configuration of the cables.

12  BSI 1996
 .. .. ..
Annex D
Annex B (normative)
Voltage test
B.1 Test for arc welding cables rated at
100 V a.c. r.m.s.
Immerse a sample of cable in water, at 20 ÊC ± 5 ÊC, for
not less than 1 h. Apply the test voltage between the
conductor and the water in which the cable is
immersed, which shall be earthed, for 15 min. The
alternating voltage shall have a frequency in the range
of 40 Hz to 60 Hz. Its wave form shall approximate to a
sine curve and both half cycles shall be reasonably
alike. The r.m.s. value of the applied voltage shall be
1000 V. Increase the voltage gradually and maintain at
the full value for 15 min without breakdown.
B.2 Test for arc welding cables rated at
450 V a.c. r.m.s.
B.2.1 Immerse a sample of cable in water, at
20 ÊC ± 5 ÊC, for not less than 12 h. Apply the test
voltage between the conductor and the water in which
the cable is immersed, which shall be earthed, for
15 min. The alternating voltage shall have a frequency
in the range of 40 Hz to 60 Hz. Its wave form shall
approximate to a sine curve and both half cycles shall
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
be reasonably alike. The r.m.s. value of the applied
voltage shall be 3000 V. Increase the voltage gradually
and maintain at the full value for 5 min without
breakdown.
B.2.2 Spark test the cable in accordance with BS 5099
with a test value of 6000 V r.m.s.. The total radial
thickness of covering shall be in accordance with
tables 6 and 7.
Annex C (normative)
Static flexibility test
C.1 Apparatus
A sample with a length of 3 m ± 0.05 m shall be tested
using test apparatus, similar to that shown in
figure C.1. Two clamps, A and B, shall be located at a
height of at least 1.5 m above ground level. Clamp A
shall be fixed and clamp B shall move horizontally at
the level of clamp A.
C.2 Procedure
Clamp the ends of the sample vertically so that they
remain vertical during the test, one end in clamp A, the
other in the movable clamp B which shall be at a
distance l = 0.20 m from clamp A.
NOTE. The cable should take approximately the shape indicated
by figure C.1 (dotted lines).
 BSI 1996
.... ... ....
..
BS 638 : Part 4 : 1996
Move the movable clamp B away from the fixed
clamp A until the loop formed by the cable takes the
shape, indicated in figure C.1 by the heavy outline, of
the U enclosed wholly between two plumb lines
through the clamps and set up tangentially to the
external generatrix of the cable. Measure the new
distance l9. The cable shall then be turned in the
clamps by 180Ê and the test repeated.
Calculate the mean value of l9.
C.3 Pre-conditioning of non-conforming samples
Wind the sample four times on and off a reel with a
diameter approximately 20 times the outer diameter of
the cable. Each time the sample shall be turned
through 90Ê.
After this pre-conditioning, the sample shall be
subjected to the test described in C.2.
Annex D (normative)
Test of the resistance to hot particles
D.1 Apparatus
D.1.1 Test device, as shown in figure D.1, to enable a
heated rod, in a horizontal position, to be applied with
a given force to a contact point on the outer cover of
the cable.
D.1.2 Rod, made of 18/8 chrome-nickel steel with a
diameter of 2.5 mm ± 0.05 mm and a length of
100 mm ± 0.5 mm.
D.1.3 Burner, consisting of a tube which is at least
35 mm long and has a bore 0.5 mm ± 0.1 mm and an
outer diameter not exceeding 0.9 mm.
NOTE. A hypodermic needle, the tapered end of which is cut off,
may be used for the test.
D.2 Procedure
Using the appropriate a.c. r.m.s. voltage, pass an
electric current of approximately 25 A through the rod
until a steady thermal state at a temperature of 300+50
ÊC is reached.
Measure this temperature by a contact thermometer or
thermocouple and maintain the temperature during the
whole test period.
Apply the rod to the outer cover of the cable with a
0
force of 1.220.2 N.
Attempt to ignite the gases emitted in the region of the
contact point with a burner and flame 100 s after the
rod has been applied to the cable, and at 10 s intervals
until the end of the test.
The burner shall be supplied with butane or propane
gas having a purity of at least 95 %. There shall be no
air admitted to the burner tube.
With the axis of the burner in the vertical position,
adjust the gas supply so that without artificial air
supply, the length of the flame is 12 mm ± 1 mm.
Continue for 2 min.
13
 .. .. .. .... ... ....
..

BS 638 : Part 4 : 1996 Annex D

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Figure C.1 Static flexibility test apparatus

14  BSI 1996
 .. .. .. .... ... ....
..

Annex D BS 638 : Part 4 : 1996

Figure D.1 Device for testing resistance to hot particles

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

 BSI 1996 15
 .. .. .. .... ... ....
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ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

16 blank
 .. .. .. .... ... ....
..

BS 638 : Part 4 : 1996

List of references

Normative references

BSI publications
BRITISH STANDARDS INSTITUTION, London

BS 499 Welding terms and symbols

BS 499 : Part 1 : 1991 Glossary for welding, brazing and thermal cutting
BS 4066 Tests on electric cables under fire conditions
BS 4066 : Part 1 : 1980 Method of test on a single vertical insulated wire or cable
BS 4727 Glossary of electrotechnical power, telecommunication, electronics,
lighting and colour terms
BS 4727 : Part 2 Terms particular to power engineering
BS 4727 : Part 2 : 1986 : Group 08 Electric cables
BS 5099 : 1992 Specification for spark testing of electric cables
BS 6360 : 1991 Specification for conductors in insulated cables and cords
BS 6469 Insulating and sheathing materials of electric cables
BS 6469 : Part 1 : Section 1.1 : 1992 Measurement of thickness and overall dimensions. Tests for
determining the mechanical properties
BS 7655 Specification for insulating and sheathing materials for cables
BS 7655 : Part 1 : Section 1.2 : 1993 General 90 ÊC application
BS 7655 : Part 2 : Section 2.3 : 1993 General application
BS 7655 : Part 2 : Section 2.4 : 1993 Welding cable covering

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
PD 2379 : 1994 Register of colours of manufacturer's identification threads for
electric cable and cords

Informative references

BSI publications
BRITISH STANDARDS INSTITUTION, London

BS 638 Arc welding power sources, equipment and accessories

BS 638 : Part 5 : 1988 Specification for accessories
BS 638 : Part 7 : 1984 Specification for safety requirements for installation and use
BS 638 : Part 8 : 1984 Specification for electrode holders and hand-held torches and guns
for MIG, MAG and TIG welding
BS 638 : Part 9 : 1990 Specification for power sources for manual arc welding with
limited duty
BS 638 : Part 10 : 1990 Specification for safety requirements for arc welding equipment:
welding power sources

CENELEC publications
EUROPEAN COMMITTEE FOR ELECTROTECHNICAL STANDARDIZATION (CENELEC), Brussels (All publications are available from
Customer Services, BSI.)

HD 22.6 S2 : 1995 Rubber insulated cables of rated voltages up to and including

450/750 V Ð Part 6: Arc welding cables
HD 22.1 S2 : 1992 Rubber insulated cables of rated voltages up to and including
450/750 V Ð Part 1: General requirements
HD 516 S1 : 1990 Guide to use of low voltage harmonized cables

 BSI 1996
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